Trailer frame

ABSTRACT

A trailer frame including an axle section having two spaced longitudinal frame members connected by at least one cross member, the longitudinal frame members each having a first end and a second end; a rear section attachable to the axle section; and a dimple assemble joining the axle section to the rear section, the dimple assembly including a dimple pattern formed on each frame member of the axle assembly, the dimple pattern on the axle assembly defining a first dimple axis, and a dimple pattern formed on one end of the rear section and nestable within the dimple pattern formed on the axle section, the dimple pattern on the rear section defining a second dimple axis offset relative to the first dimple axis to create a camber between the axle section and the rear section when the first dimple is nested within the second dimple pattern.

CONTINUING APPLICATION DATA

This application is a continuation-in-part of co-pending U.S.application Ser. No. 13/294,685 filed Nov. 11, 2011 which is herebyincorporated by reference.

TECHNICAL FIELD

The present invention generally relates to trailer frames, and moreparticularly to bolt-together trailer frames. More particularly, thepresent invention relates to a trailer frame having an enhanced axlesection. Most particularly, the present invention relates to a trailerframe where the camber between an axle section and an adjacent sectionis set by a dimple pattern.

BACKGROUND OF THE INVENTION

Typically trailer frames are manufactured by welding frame memberstogether. Typical frame members include I-beam, flat, L-shape, U-shapeor tubular rail sections. The frames generally have a ladderconstruction with axle units connected to the side frame members of theladder near the center or rearward portion of the frame. These trailerframes are used for boat trailers, car trailers, recreational vehicles,horse trailers, utility trailers, and the like.

Since the entire frame, including the axle is pre-assembled, shippingmay be difficult with only a few assembled frames being shipped at anytime. In most cases, frames are built on a made to order basis to avoidmaintaining pre-assembled frames in inventory.

It is desirable to have camber within the frame typically at therearward end of the frame to accommodate loads placed on the frame. Whenloaded, the frame will deform. To level the load on the frame, existingmanufacturers heat the frame to cause it to deform and create camber.Existing frames are ladder frames having a pair of I-beams that extendthe length of the frame. To create positive camber at the rear of such aframe, for example, a weld is placed along the top side of the framemembers between the axles and the rear end of the frame to draw the rearend up. Once positive camber is created, water is thrown onto the weldto rapidly cool it and lock the camber in place. Since relying on theheat of the weld to create camber is imprecise, additional welding maybe used to adjust the camber to a suitable amount. This method ofcreating camber alters the material properties of the metal at the weldand may make the frame more susceptible to failure. Alternatively, theframe members may be pounded or otherwise mechanically deformed toachieve the desired camber. It will be appreciated that the variablesinvolved in either method prevent any consistency in the amount ofcamber achieved for each trailer frame.

SUMMARY OF THE INVENTION

The present invention generally provides trailer frame including an axlesection having two spaced longitudinal frame members connected by atleast one cross member, the longitudinal frame members each having afirst end and a second end; a rear section attachable to the axlesection; and a dimple assemble joining the axle section to the rearsection, the dimple assembly including a dimple pattern formed on eachframe member of the axle assembly, the dimple pattern on the axleassembly defining a first dimple axis, and a dimple pattern formed onone end of the rear section and nestable within the dimple patternformed on the axle section, the dimple pattern on the rear sectiondefining a second dimple axis offset relative to the first dimple axisto create a camber between the axle section and the rear section whenthe first dimple is nested within the second dimple pattern.

The present invention further provides a trailer frame having anenhanced axle section is provided. The axle section has a pair of boxedframe rails. Each frame rail includes a first frame half and a secondframe half that are joined together to define a central cavity. At leastone cross member extends between the pair of boxed frame rails to jointhem together.

The present invention further provides a trailer frame including an axlesection having two longitudinal frame members on each side of the axlesection that are connected by at least one cross member, the twolongitudinal frame members each include a first end and a second endthat each have a plurality of axle dimples, and the axle section havinga means for securing at least one axle; a front section having a frontcross member and two longitudinal frame members on each side of thefront section, the two longitudinal frame members each include a firstend fixedly secured to the front cross member and a second end having aplurality of front dimples in nested engagement with the plurality ofaxle dimples on the first end of the axle section; and a rear sectionhaving a rear cross member and two longitudinal frame members on eachside of the rear section, the two longitudinal frame members eachinclude a first end fixedly secured to the rear cross member and asecond end having a plurality of rear dimples in nested engagement withthe plurality of axle dimples on the second end of the axle section,wherein camber of the trailer frame is preset in at least one of thefollowing: the plurality of dimples on the rear section and theplurality of dimples on the front section.

The present invention still further provides a torsion suspensionassembly for a trailer frame including an elastomeric element, theelastomeric element defining a central bore and plural pin receivingbores located on a circle spaced radially outward from the central bore,a cylindrical journal received in the central bore in the elastomericelement, an outer end cap and an inner end cap, wherein the outer andinner end caps are adapted to enclose at least a portion of theelastomeric element, each end cap having at least one pin extendinginward therefrom, wherein the pins from the outer and inner end caps arereceived in respective pin receiving bores, each pin extending an extentsuch that a portion of the pin on the outer end cap overlaps a portionof the pin on the inner end cap within the elastomeric element, each endcap defining an axle mount bore having a non-circular shape, and an axlemount having a non-circular cross section insertable through the axlemount bores in the end caps and rotatably received in the cylindricaljournal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a trailer according to theinvention.

FIG. 2 is a side elevational view of a trailer according to theinvention.

FIG. 3 is an enlarged side elevational view showing details of a jointin a trailer according to the invention.

FIG. 3A is a schematic view showing an axle section having a dimplepattern defining a dimple axis and a rearward section having a dimplepattern offset relative to the dimple pattern on the axle section todefine an offset dimple axis, where the offset has been exaggerated forpurposes of illustration.

FIG. 4 is a sectioned top plan view showing further details of a jointin a trailer according to the invention.

FIG. 5 is an exploded view showing details of a cross member in atrailer according to the invention.

FIG. 6 is a partially sectioned view of an axle section of a trailerframe having a torsion disk suspension assembly mounted thereon.

FIG. 7 is an exploded view of a torsion disk suspension assemblyaccording to the invention.

FIG. 8 is a sectioned view of the torsion disk suspension assembly.

FIG. 9 is a bottom perspective view of a trailer frame according to theinvention partially exploded to show details of an alternative jointbetween the adjacent sections of the trailer frame.

FIG. 10 is a bottom perspective view of the alternative trailer framewith the adjacent sections attached to each other.

FIG. 11 is a side elevational view of the joint between the adjacentsections shown in FIG. 10.

FIG. 12 is a section view as might be seen along line 12-12 in FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

A trailer frame 10 according to the invention is depicted in theaccompanying drawings. Trailer frame 10 is divided into plural sections.The sections are connected by a dimple assembly 30. The dimple assembly30 may be used to set the camber between sections as described morecompletely below.

Trailer frame 10 may be assembled from plural rails or side framemembers 12 and one or more cross members 14. A tongue assembly 15 may beattached to facilitate coupling of trailer frame 10 to a vehicle. Theconfiguration of tongue assembly 15 may vary depending on the vehicle towhich tongue assembly 15 is attached or the application for trailerframe 10. Likewise, floor supports our outriggers 16 may be attached toside frame members 12 as needed for a particular application. Trailerframe 10 may include a bumper assembly 18.

Trailer frame 10 includes multiple sections that are joined together.For example, trailer frame 10 may include an axle section 20, a forwardsection 22 and a rearward section 24. It will be appreciated that frame10 may include fewer or more sections. In the example shown, axlesection 20 is located between forward section 22 and rearward section24. As shown in FIG. 2, axle section 20 includes an axle assembly 25,which may be a sprung unit or a torsion unit, having one or more axleswith wheels 26 operatively supported thereon.

Two sections are attached to each other by a dimple assembly 30. As bestshown in FIGS. 3 and 4, dimple assembly 30 may include one or moredimples 32 formed on each frame member that nest within each other toconnect frame members from each section. Dimples 32 may have any shapeincluding, geometric shapes, oblong, or irregular shapes. The circularshape shown is just one example. One or more dimples may be used todefine a dimple pattern, generally indicated at 35. The dimple pattern35 defines a dimple axis 34 which generally represents a major directionof dimple pattern 35. Dimple pattern 35 may, thus, be used to controlthe orientation of sections relative to each other. For example, dimplepattern 35 on one frame member may be offset relative to the dimplepattern 35 on another frame member, such that when the frame members arejoined by nesting one dimple pattern in the other, the frame members ofrespective sections are placed in a desired orientation. For example,dimple pattern 35 on one frame member may have a dimple axis arranged atan angle relative to a dimple pattern 35 on another frame member tocreate positive/negative camber between adjacent sections. According toanother aspect of the invention, the spacing between dimples 32 may bevaried in the vertical and horizontal directions to optimize the loadingof dimples 32 as well.

Any number of dimples 32 may be used and in any configuration. Theexamples provided are, therefore, not limiting. Increasing the size ornumber of dimples increases the surface over which the load is spread,and therefore, larger or greater numbers of dimples 32 may be used tohandle greater loads. Smaller or fewer dimples may be used for smallerloads. In the example shown, dimple pattern 35 includes three columns(A,B,C) of dimples 32. Columns A,B,C may include more than one row ofdimples 32. For example, as shown, two rows of dimples 32 may be used.The dimples 32A, 32B in first and second rows are arranged parallel toeach other. The third column C of dimples 32 may be offset relative tocolumns A,B. For example, dimples 32C in third column C may be locatedcloser to the center of a side frame member at 36. Also, the spacing(BC) between dimples in columns B and C may be reduced in comparison tothe spacing (AB) between columns A and B, as shown. In the exampleshown, the centers of the dimples in column C are located 0.25 inchinward relative to corresponding dimples 32 in column B. Also, thecenters of dimples 32 in column C are spaced 0.5 inches closer to thecenters of dimples 32 in column B when compared to the spacing betweencolumns A and B. An exemplary spacing may be 3.5 inches between columnsA and B and 3.0 inches between columns B and C. The rows of dimples 32in columns A and B may be vertically spaced 2.5 inches on center, whilethe dimples 32 in column C are vertically spaced 2.0 inches on center.It will be appreciated that the spacing between individual dimples 32 incolumn C do not need to be uniform with each dimple 32 having adifferent offset depending on the application or desired loading to beachieved. In the depicted example, finite element analysis shows thatplacing the dimples in third column C closer to the center and nearer tothe dimples 32B drives the load toward the top and bottom flangesminimizing deflection of the side wall of the frame members.

With reference to FIG. 4, dimples 32 may have an outwardly openingfrusto-conical section. Dimple 32 may be stamped into the section suchthat a base 40 is located inward of the outer wall of the frame member.As shown, base 40 may be circular and define a central opening 42 thatreceives a fastener 44, such as a Huck® bolt or the like. A dimple wall46 extends axially and radially outward from base 42. When assembled,the load transfer between dimples 32 occurs at walls 46 of eachrespective dimple 32. As best seen in FIG. 4, which shows two framemembers fastened together at dimples 32, with the fastener 44 removed onthe left to show greater detail of the dimples 32, a small gap 48 maylie between each base 42 of dimples 32.

As shown in FIGS. 1 and 2, dimples 32 may be formed on any surface tojoin frame members together. For example, a planar surface such as theupstanding sidewall of a frame member may be used. Dimple size may varydepending on the surface to which the dimple 32 is applied, the numberof dimples used, and the amount of loading on the dimple 32. In theexample shown, dimples 32 are located on an upstanding side wall of theaxle section 20 and an adjacent forward section 22 and rearward section24. Axle section 20 has dimple patterns 35 at each end that mate withdimples 32 on the forward and rear sections 22, 24. It will beappreciated that each section 20, 22, 24 of trailer frame 10 may havevarious lengths and cross-sections.

In the example shown, axle section 20 includes axle rails 50 on eitherside connected by one or more cross members. Axle section may beconstructed in any known manner. According to another aspect of theinvention, an enhanced axle section 20 is provided. Enhanced axlesection 20 has axle rails 50 having a box-like cross section. Thiscross-section may be formed in a number of manners including by weldingan inner sidewall to a c-shaped channel. Alternatively, as best seen inFIG. 6, each axle frame member 50 may be formed from a pair of framehalves 50A,50B. First frame half 50A may have a c-shaped section withtop and bottom walls 53, 54 extending inward from an outer sidewall 51.Outer sidewall 51 and top and bottom walls 53, 54 may be formed as asingle unit, for example by stamping, or constructed by joiningindividual components together. The second frame half 50B is alsoc-shaped having an outer side wall 52 with an upper lip 55 that fitsover top wall 53 and extends beyond inner side wall 51 to match thewidth of the front and rear section frame members that attach to axlesection 20. A downward extending tab 57 may be formed on the end of lip55 to form a channel like section and add strength to lip 55. Secondframe half 50B also includes a lower lip 58 that extends outward tooverlie bottom wall 54. The first and second halves 50A,50B may bejoined by welds at the seams between top wall 53 and lip 55 and bottomwall 54 and lower lip 58. Each frame member 50 defines a cavity that isopen at either end. As discussed below, the cavity 170 may be used tohouse suspension components. An suspension opening 171 may be providedin one or more of side walls 51,52 to facilitate mounting of suspensioncomponents.

The box-like construction of axle rail 50 makes it resistant totorsional forces and less prone to racking when compared to existingI-beam frames. In addition, the box-like construction may be used tohouse and incorporate suspension components. For example, a torsion disksuspension may be inserted at either end of the axle section 20.Alternatively, suitable suspension mounts 59 (FIG. 2) may be providedfor traditionally sprung axles.

As discussed, a dimple assembly 30 may be used to join one or more framesections to axle section 20. In the axle section 20 shown, dimples 32forming dimple patterns 35 at one or more ends of axle section 20 arestamped into outer sidewall 51 of first frame half 50A before attachingsecond frame half 50B. The dimple assembly 30 is mated to correspondingdimples 32 on forward and rearward sections 22,24. While attachment ofthese sections is shown on outer sidewall 51, it will be appreciatedthat attachment may occur at the interior side 52 as an alternative.

Forward section 22 and rearward section 24 may include rails 26, 28 thathave any cross-section, and may have cross-sections that are differentfrom each other depending on the application. In the example shown, thecross-section of the rails 26, 28 of the forward and rearward sections22, 24 are the same. Rails 26, 28 include an upstanding side wall 62having a top wall 64 extending laterally outward and a bottom wall 66extending laterally inward from the upper and lower extremities ofsidewall 62. This cross-section may be referred to as a Z-shapedsection. A first flange 67 may extend downward from an outer extremityof top wall 64 and a second flange 68 may extend upward from an innerextremity of bottom wall 66. Flanges 67, 68 form channel like sectionsat respective upper and lower extremities of rails 26, 28 improving thestrength and torsional rigidity of the forward and rearward sections 22,24.

As in the axle section 20, dimples 32 may be formed on the side wall 62of forward and rearward sections 22, 24. To set the camber betweenadjacent sections, the dimple pattern on each section may be offsetrelative to the dimple pattern 35 on axle section 20. In the exampleshown, the dimple pattern 35 on the axle section 20 is fixed and theorientation of the dimple pattern 35 on forward and rearward sections22, 24 is varied to create camber. It will be appreciated that thedimple pattern 35 on axle section 20 may be varied as well. The dimples32 may be formed in any known manner including stamping.

As discussed above, for some applications, it is desirable to createcamber between adjacent sections. Positive or negative camber in thiscontext is a deviation from horizontal or zero camber. When a load isplaced on a trailer frame, the frame deflects under the load. Tomaintain the load in a level configuration, it may be necessary toimpart camber to the front or rear section.

The present invention overcomes the failings in the art by pre-settingthe camber between adjacent sections through the dimples 32. A desiredcamber angle α in many applications has an absolute value of 0 to about2 degrees, or in other words between about −2 degrees and about +2degrees of camber. This range is not limiting, however, as greateramounts of camber may be set using a dimple pattern 35 according to theinvention.

In the example shown, positive camber is created at the rearward section24 relative to axle section 20 by shifting the dimples 32 on rearwardsection 24 downward relative to the position of the dimples 32 on axlesection 20. As shown in FIG. 3A, the dimple pattern 35 on rearwardsection 24 defines a dimple axis 34′ having a downward angle such thatwhen the dimples 32 of rearward section 24 are aligned with dimples 32on axle section 20, the rearward section 24 is angled upward relative toaxle section 20 (FIG. 3). In the example shown, the dimple pattern 35 onaxle section 20 is fixed or constant and the dimple pattern 35 on theforward or rearward sections 22, 24 is offset to create the desiredcamber. In this way a single axle section 20 may be mass produced andcamber specifications met by stamping the dimple pattern into theforward or rearward sections 22, 24. It will be appreciated, however,that camber may be created by offsetting the dimple pattern 35 on axlesection relative to one or both of the forward and rearward sections 22,24 or by applying an offset to dimple patterns 35 on both the axlesection 20 and forward or rearward sections 22, 24. Any angle may beachieved in this manner.

The camber angle over the length of the section causes the end of thesection to be at a different height than the adjacent section. Often,customers will specify a desired change in height rather than a specificcamber angle. The specified change in height may be used to calculatethe camber needed at the dimples 32. In the example shown, a camber ofabout 1 degree may be used to achieve a one inch increase in the heightof the rearward section 24 at its outer end.

According to another aspect of the invention, trailer frame 10 includescross frame members 14 that have a truss-like form. In particular, crossframe member 14 includes a top cross member 72 a bottom cross member 74and a web section 76. Cross member 14 may further include end members 78that extend between the top and bottom cross members 72, 74 at theirouter extremities. As best shown in FIG. 5, top and bottom cross members72,74 may be formed from angle iron. Angle iron may be extruded orotherwise formed to any length needed for a given trailer application.The web section 76 may be constructed of individual members that connectthe top cross member 72 and bottom cross member 74, or, as shown, beconstructed from one or more, pre-formed patterned members 80. Usingplural patterned members 80 allows any length cross member 72 to becreated without the need for a large die to create the web 76 and withless labor than assembling a web with individual trusses.

In the depicted example, each patterned members 80 include pluraltrusses 82 that extend at an angle relative to cross members 72, 74.Trusses 82 may be joined at the upper and lower extremities by a land 84to form a wave-form shaped patterned member 80. To facilitate connectionof patterned members 80 to each other and to ends 78, tabs 86 may beprovided at the lateral extremities of patterned members 80. Top tabs 88may be provided at the upper extremity of the patterned member tofacilitate attachment of web section to top cross member(s) 72. Bottomtabs 90 may be provided to facilitate attachment of web section 76 tobottom cross member 74. Upper and lower peak tabs 92, 94 may be providedto span the interior portion where trusses 82 come together. As shown,one or more of tabs 92 may be provided with openings 96 for fasteners.As shown, the patterned member 80 may be formed as a single unit, as bystamping or in a mold. To accommodate different lengths, multiplepatterned members 80 may be used within a given cross frame member 14.As shown, a pair of patterned members 80 may be joined to each other toform a web 76.

Attachment of the web 76 to top cross member 72 and bottom cross member74 may be accomplished in any known manner including fasteners or welds.In the example shown, welds are applied at each land 84 to join topcross member 72, bottom cross member 74, and web 76. Ends 78 may,likewise, be attached in any known manner. In the example shown,fasteners (not shown) extend through openings 98 formed on an inwardextending tab portion 100 of end 78, and corresponding end openings 102formed on a downward extending leg 104 of top cross member 72 and anupward extending leg 108 of bottom cross member 74. Side openings 110may be provided on ends 78 to attach cross frame member 14 to side framemembers in trailer frame 10 with fasteners.

In accordance with another aspect of the invention, trailer frame 10 mayinclude a torsion disk suspension 120. Torsion disk suspension 120generally includes a suspension cartridge 121 that is inserted withinthe cavity 170 defined by a longitudinal frame member 50 in axle section20. During assembly, the suspension cartridge 121 is inserted at eitherend of frame member 50 and aligned with a suspension receiver 58. Asuspension mount may pass through receiver 58 and through suspensioncartridge 121 to support it within frame member 50.

According to one embodiment, suspension cartridge 121 includes anelastomeric element 122 with plural pin receiving bores 124 arrangedaround a central axle bore 126. It will be appreciated that elastomericelement 122 does not need to have a circular disk shape and thereforereference to a disk suspension should not be limiting terms of the shapeof the elastomeric element, which may have any shape capable ofproviding elastomeric material surrounding plural pin receiving bores.

Suspension 120 may further include an outer cap 130 and an inner cap132, which may be received in respective openings defined in the outersidewall 51 and inner sidewall 52 of axle rail 50. The caps 130, 132enclose elastomeric element 122. Outer cap 130 has one or more outerpins 136 extending inward therefrom, and inner cap 132 has inner pins138 extending inward therefrom. Pins 136, 138 are received in respectivepin receiving bores 124. As best shown in FIG. 6, pins 136, 138 extendinwardly an extent sufficient to overlap one another. In the exampleshown each cap 130, 132 is provided with three pins 136, 138. The pins136 and 138 are spaced about a pin circle to form an alternatingarrangement of outer pins 136 and inner pins 138 about the elastomericelement 122.

An axle mounting assembly 140 may be received in axle bore 126 andincludes a journal 142 having a cylindrical outer surface 144 and asquare bore 146. Outer end cap 130 and inner end cap 132 havecorresponding square bores through which a square sectioned axle mount150 is received. A portion of axle mount 150 extends outwardly fromouter sidewall 51 and may be secured by a castle nut 152. An axleassembly 160 is supported on axle mount 150. Axle assembly may includean axle arm 162 that has a corresponding axle mount receiver 163 thatconforms to axle mount such that torque created at axle 165 istransmitted to the elastomeric element through axle mount 150. Axle arm162 extends downward and rearward from torsion suspension 120 such thatany vertical movement of the axle 165 creates a torsional moment at thesuspension 120. In particular, vertical movement of axle 165 causesouter end cap 130 to rotate, which in turn causes outer pins 136 torotate within elastomeric element 122. Compression of the elastomericelement between pins 136 and 138 absorbs shock and creates a returnmoment that urges the axle 165 toward the road surface.

With reference to FIGS. 9-12 an alternative trailer frame 210 is shown.Trailer frame 210 includes an axle section 220. A forward section 224may be attached to axle section 220 in the same manner as the rearwardsection 224 shown or another form of attachment may be used. In theexample shown, the joint assembly for the forward section and therearward section is the same and will be discussed in connection withthe rearward section 224 being attached to the axle section 220. Inaccordance with another embodiment of the invention, maximizing thespacing between dimples has been found to improve the load carryingcapacity and strength of the joint. In particular, a correlation betweenthe spacing of the dimples and the strength of the joint was found. As aresult, strength is maximized by placing the dimples as far from eachother as the confines of the frame section will allow. While thefollowing description discusses a dimple pattern having plural dimples,it will be appreciated that a single dimple may be used. To achieve thespacing discussed, the single dimple may be a ring-like shape with thedimple being formed at the periphery of the joint in a continuous form.

With reference to FIG. 11, a dimple assembly 230 having plural dimplesforming a dimple pattern 235 is shown. In particular, a dimple pattern235 comprised of four dimples 232 is shown. The dimples 232 form tworows and two columns with each dimple being equally spaced verticallyand horizontally from each other. In the vertical direction, the spacingof dimples 232 is limited by the height of the frame sections 220, 224being joined. To maximize the vertically spacing, dimples 232 arelocated near the upper and lower extremities of the frame sections 220,224. Horizontally, the spacing of dimples 232 may be maximized byplacing the dimples at the outer extremities of the frame membersforming the joint J. It will be appreciated, however, that the jointformed between the adjacent sections 220, 224 may not span the entirelength of one or both sections. For example, as shown, interveningstructures such as mounts for axles and other structures may limit theamount of overlap between adjacent sections 220, 224 in this sense, thestrength of the joint is maximized by placing the dimples as close tothe edges of the overlapping joint. In a general sense, the spacing ofdimples 232 is maximized by placing them near the extremities (upper,lower, inner or outer) of the joint. As best seen in FIG. 11, the jointJ is defined by the overlap between the ends of axle section 220(trailing edge T) and rearward section 224 (leading edge L). It will beappreciated that similar overlap may occur at a forward section, ifused. In the vertical direction, the overlapping encompasses the entireheight of each sidewall 262 of frame sections 220,224, such that theupper and lower extremities of joint J coincide with the upper and lowerextremities of sidewalls 262. Horizontally, the spacing of dimples ismaximized by placing the dimples near the inner and outer extremity ofjoint J i.e. near the trailing edge T of a first frame member (axlesection 220) and the leading edge L of a second frame member (rearwardsection 224). It will be understood, that the spacing between dimpleswill vary depending on the size of the frame members with smaller framemembers bringing the dimples closer to each other than on a larger framemember. In addition, the spacing may be varied to accommodate otherframe components (cross members, outriggers, tank hangers, suspensioncomponents etc.) that may be in the way. In addition, the spacing may bevaried based on load. For example, a large frame may carry a reducedload allowing for a smaller spacing between dimples. In the exampleshown, the spacing is maximized for the trailer frame size with spacingfrom the extremities of the joint J provided to accommodate surroundingstructures including the Huck® fasteners and suspension mountingbrackets. In the vertical direction, the spacing of the center of thedimples is the frame member (rail) height minus 2.75 inches. Forexample, 6 inch rail has 3.25 inch vertical spacing; 7.5 inch rail has4.75 inch vertical spacing; 9 inch rail has 6.25 inch vertical spacingetc. It will be appreciated that a larger spacing may be achieved whenless clearance is required for the fasteners, for example, when railsare welded together. Horizontally the spacing for a 6 inch rail is about3 to 5 inches. Measuring from the end of the frame member, for the fourdimple pattern shown, the first column of dimples is located 4 inchesfrom the edge and the second column is 8 inches from the edge for a 6inch frame member; 7 inches from the edge and 10 inch from the edge fora 7.5 inch frame member; and 7 inches from the edge and 10 inches fromthe edge for a 9 inch frame member. Considering the spacing between thedimple centers, the 6 inch 7.5 inch and 9 inch frame members include avertical spacing V of the dimples ranging from about 2.75 inches to 4.75inches and the horizontal spacing H between the dimples ranging fromabout 3 inches to about 4 inches. It will be appreciated that theseranges are not limiting. In a low load scenario, the dimples may beplaced next to each other i.e. 0 spacing in both vertical and horizontaldirections, and the upper limit of the spacing is only limited by theframe rail size. Consequently, to achieve larger vertical spacing, alarger frame member would be used.

As discussed, the example shown has equal vertical spacing between allof the dimples and equal horizontal spacing between all of the dimplesforming a regular rectangular pattern. It will be appreciated that thespacing between the dimples and pattern may be unequal or varied acrossthe pattern as discussed in the earlier embodiment.

Dimple pattern 235 on adjacent sections may be used to create camberbetween adjacent sections 220 and 224 in the same manner as discussed inthe previous embodiment. In particular, the axes defined by dimplepattern 235 on axle section 220 and the dimple pattern 235 on rearsection 224 may be offset relative to each other by an angle to createthe desired camber between the sections 220, 224. The offset may becreated by offsetting one of the dimple patterns by the desired angle orby offsetting each of the dimple patterns a portion of the desired anglesuch that when the dimples are nested within each other the cumulativeoffset produces the desired camber angle.

Moreover, as discussed in the previous embodiment, rearward section 224may include rails 226, 228 that have an cross section including crosssections that are different from the other sections from trailer frame210 including axle frame 220. Or, as shown, axle section 220 andrearward section 224 may have the same cross section as best seen inFIG. 12, each section 220, 224 has an upstanding sidewall 262 a top wall264 extending laterally outward from sidewall 262 and a bottom wall 266extending laterally inward from sidewall 262. This cross section may bereferred to as a Z-shaped section. A first flange 267 may extenddownward from an outer extremity of top wall 264 and a second flange 268may extend upward from an inner extremity of bottom wall 266. Flanges267, 268 form channel-like sections at respective upper and lowerextremities of rails 226, 228 improving the strength and torsionalrigidity of the strength and torsional rigidity of the rearward section224 and axle section 220. To set the camber between sections 220 and224, the dimple pattern 235 on rearward section 224 may be offsetrelative to the dimple pattern 235 on axle section 220. In the exampleshown, the dimple pattern 235 on axle section 220 has a horizontal majoraxis that bisects the rows of dimples 232. The dimple pattern formed onthe sidewall 262 on rearward section 224 is offset such that the majoraxis of dimple pattern 235 on rearward section 224 extends at an anglerelative to horizontal. As discussed in the previous embodiment, theamount of offset may be used to create any desired camber angle havingan absolute value of 0° to 90°. Although large camber angles arepossible, typical camber angles used have an absolute value of about 0°to about 2°, or in other words, between −2° and about +2° of camber.This range is not limiting, however, as greater amounts of camber may beset by using a dimple pattern 235 according to the invention.

In the example shown, a positive camber is created at rearward section224 relative to axle section 220 by shifting the dimples 232 on rearwardsection 224 downward relative to the position of dimples 232 on axlesection 220. As in the previous embodiment, dimple pattern 235 on axlesection 220 is fixed or constant and the dimple pattern 235 on adjacentsections, such as, rear ward section 224 is offset to create the desiredcamber. In this way, a single axle section 220 may be mass produced andcamber specifications met by varying the dimple pattern into forward orrearward sections attached to axle section 220. It would be appreciated,however, that camber may be created by offsetting the dimple pattern 235on axle section relative to one or both of the forward or rearwardsections or by applying an offset to the dimple pattern 235 on both theaxle section 220 and the forward or rearward sections attached thereto.Any angle maybe achieved in this manner.

To attach adjacent sections together, a fastener including but notlimited to a weld, adhesive or mechanical fastener may be used. In theexample shown, a mechanical fastener is used to clamp adjacent framemembers together at dimples 232. To that end, dimples 232 may include acentral opening 242 through which a fastener 244, such as a Huck® boltor the like, is received. Dimples 232 may have any shape includinggeometric shapes, oblong, or irregular shapes. The circular shape shownis just one example. As shown, dimples 232 may have an outwardly openingfrusto-conical cross section and may be stamped into the sidewall 262 ofa frame section, such that a base 240 of dimple 232 is located inward ofsidewall 262. Dimples 232 may be formed by other known machiningprocesses as well. A dimple wall 246 extends axially outward from base242 of dimple 232. The dimple size may vary depending on the surface towhich the dimple is applied, the area of the joint, and the number ofdimples used. Also, the dimple size may depend somewhat on the loadingof the dimple. Therefore, the dimples 232 shown are not limiting.

According to another aspect of the invention, a reinforcement assembly280 may be provided at one or more of the top wall 264 or bottom wall266. In the examples shown, reinforcement assembly 280 is provided ontop wall 264 at the joint J between adjacent frame sections. Inparticular, reinforcement assembly 280 is provided where the top wall264 of axle section 220 and rearward section 224 meet. As best seen inFIG. 9, top wall 264 of axle section 220 terminates at the joint areasuch that the joint area of axle section 220 does not have an outwardextending wall at its upper extremity along the portion corresponding tothe overlap between axle section 220 and rearward section 224. As bestseen in FIG. 11, top wall 264 terminates at a point on axle section 220corresponding to where the leading edge L of rearward section 224overlaps axle section 220. With reference to FIG. 12, the top wall 264of rearward section 224 extends over sidewall 262 of axle section 220 inthe joint area. The reinforcement assembly 280 includes a plate 282sized to fit within the space between flange 267 and sidewall 262beneath top wall 264 of each section. As shown, a first portion 284 ofplate 282 lies beneath top wall 264 of axle section 220 and a secondportion 286 lies beneath a portion of top wall 264 of rearward section224. Each portion 284, 286 may be attached to the respective top walls264 of axle section 220 and rearward section 224. Attachment may be madeby any fastener including but not limited to mechanical fasteners,welds, or adhesives. For example, plate 282 is provided with pluralreceivers 290 through which mechanical fasteners, such as, Huck® boltsare inserted to clamp the top wall 264 one or more of the frame sections220,224 to plate 282. As shown, combinations of multiple fastener typesmay be used to facilitate assembly. For example, as shown in FIG. 9,plate 282 may be tack welded to axle section 220 at 292 and a pair ofreceivers 290 are provided in a second portion 286 of plate 282. Huck®bolts extend through top wall 264 of rearward section 224 to attach itto second section 286 of plate 282.

Plate 282 may have any thickness depending upon the amount ofreinforcement required. As best seen in FIG. 12, the thickness of plate282 may be greater than the thickness of top wall 264. For example, thethickness of plate 282 may be at least twice the thickness of top wall264. With reference to FIGS. 9 and 10, as shown, the same reinforcementassembly 280 may be provided at the opposite end of axle section 220 foruse in connection with a forward section of the trailer 210 as discussedin the previous embodiment. In the example shown, the reinforcementassembly 280 is fixed to the axle section 220 such that the use offasteners is only on the adjacent sections, such as, reward section 224.It will be appreciated however, that the reverse arrangement may be usedor the reinforcement assembly 280 may be attached separately withmechanical fasteners extending through each portion 284, 286.

As used herein, spatially orienting terms such as “above,” “below,”“upper,” “lower,” “inner,” “outer,” “right,” “left,” “vertical,”“horizontal,” “top,” “bottom,” “upward,” “downward,” “laterally,”“upstanding,” et cetera, can refer to respective positions of aspects asshown in or according to the orientation of the accompanying drawings.“Inward” is intended to be a direction generally toward the center of anobject from a point remote to the object, and “outward” is intended tobe a direction generally away from an internal point in the objecttoward a point remote to the object. Such terms are employed forpurposes of clarity in describing the drawings, and should not beconstrued as exclusive, exhaustive, or otherwise limiting with regard toposition, orientation, perspective, configuration, and so forth.

Embodiments herein can be constructed of various materials. One or moreportions of a trailer frame can be made of (but are not limited to)different types of plastic, metal, ceramic, rubber, glass, carbon, fiberreinforced or other composites, and other suitable materials. Wherenecessary or desirable (e.g., with rotating or folding embodiments),known structures such as rails, hinges, springs, and others can beemployed with aspects herein without departing from the scope or spiritof the innovation.

Specific embodiments of an innovation are disclosed herein. One ofordinary skill in the art will readily recognize that the innovation mayhave other applications in other environments. In fact, many embodimentsand implementations are possible. The following claims are in no wayintended to limit the scope of the subject innovation to the specificembodiments described above. In addition, any recitation of “means for”is intended to evoke a means-plus-function reading of an element and aclaim, whereas, any elements that do not specifically use the recitation“means for”, are not intended to be read as means-plus-functionelements, even if the claim otherwise includes the word “means”.

Although the subject innovation has been shown and described withrespect to a certain preferred embodiment or embodiments, it is obviousthat equivalent alterations and modifications will occur to othersskilled in the art upon the reading and understanding of thisspecification and the annexed drawings. In particular regard to thevarious functions performed by the above described elements (e.g.,enclosures, sides, components, assemblies, etc.), the terms (including areference to a “means”) used to describe such elements are intended tocorrespond, unless otherwise indicated, to any element which performsthe specified function of the described element (e.g., that isfunctionally equivalent), even though not structurally equivalent to thedisclosed structure which performs the function in the hereinillustrated exemplary embodiment or embodiments of the innovation. Inaddition, while a particular feature of the innovation may have beendescribed above with respect to only one or more of several illustratedembodiments, such feature may be combined with one or more otherfeatures of the other embodiments, as may be desired and advantageousfor any given or particular application. Although certain embodimentshave been shown and described, it is understood that equivalents andmodifications falling within the scope of the appended claims will occurto others who are skilled in the art upon the reading and understandingof this specification.

In addition, while a particular feature of the subject innovation mayhave been disclosed with respect to only one of several implementations,such feature may be combined with one or more other features of theother implementations as may be desired and advantageous for any givenor particular application. Furthermore, to the extent that the terms“includes,” “including,” “has,” “contains,” variants thereof, and othersimilar words are used in either the detailed description or the claims,these terms are intended to be inclusive in a manner similar to the term“comprising” as an open transition word without precluding anyadditional or other elements.

What is claimed is:
 1. A trailer frame comprising: an axle sectionhaving at least one frame member having a first end and a second end; arearward section having at least one frame member having a first end anda second end, wherein the rearward section is attachable to the axlesection; and a dimple assembly joining the axle section to the rearwardsection, the dimple assembly including a dimple pattern formed on the atleast one frame member of the axle assembly, the first dimple pattern onthe axle assembly defining a first dimple axis, and a second dimplepattern formed on one end of the at least one frame member of therearward section and nestable within the first dimple pattern formed onthe axle section, the second dimple pattern on the rearward sectiondefining a second dimple axis offset relative to the first dimple axisto create a camber between the axle section and the rearward sectionwhen the first dimple pattern is nested within the second dimplepattern; wherein each of the frame members of the axle section and therearward section carrying the respective first and second dimplepatterns include an upstanding sidewall and wherein the sidewall of theaxle section and the sidewall of the rearward section overlap at ajoint, wherein the dimple pattern on the axle section is formed on thesidewall of the rearward section and the dimple pattern on the rearwardsection is formed on the sidewall of the rearward section; wherein thefirst dimple pattern of the axle section and the second dimple patternof the rearward section each include plural dimples and wherein thedimples are located near an outer extremity of the joint.
 2. The trailerframe of claim 1, wherein each dimple has a circular base, the basedefining a central opening adapted to receive a fastener that securesthe first dimple pattern to the second dimple pattern.
 3. The trailerframe of claim 1, wherein the camber between the axle section and therear section has an absolute value from 0° to about 2°.
 4. The trailerframe of claim 1, wherein the axle section and the rearward sectioninclude a pair of laterally spaced longitudinal frame members, whereinthe dimple pattern of the axle section is formed in each of thelongitudinal frame members of the axle section and the dimple pattern ofthe rearward section is formed in each of the longitudinal frame membersof the rearward section.
 5. The trailer frame of claim 1, wherein theplural dimples are spaced vertically by an amount equal to a height ofthe sidewall minus 2.75 inches.
 6. The trailer frame of claim 1, whereina vertical spacing between the plural dimples in each said dimplepattern ranges from about 2.75 inches to about 4.75 inches.
 7. Thetrailer frame of claim 1, wherein a horizontal spacing between theplural dimples in each said dimple pattern ranges from about 3 inches toabout 5 inches.
 8. The trailer frame of claim 1, wherein each of saidfirst dimple pattern and said second dimple pattern includes fourdimples arranged in two columns and two rows.
 9. The trailer frame ofclaim 8, wherein the four dimples define a rectangular dimple pattern.10. The trailer frame of claim 1, wherein each dimple pattern includesthe plural dimples having a circular base and conical wall extendinginward from the sidewall on the respective frame members on the axlesection and the rearward section.
 11. The trailer frame of claim 10,wherein the base of each said dimple defines an opening adapted toreceive a fastener, wherein when the dimple patterns are nestedtogether, the openings of each said dimple on the axle section alignwith a respective one of the openings on the rear section.
 12. Thetrailer frame of claim 1 further comprising a reinforcement assemblysupported on the axle section opposite the rearward section, wherein aportion of the reinforcement assembly overlies and attaches to a portionof the rearward section, when the rearward section is attached to theaxle section.
 13. The trailer frame of claim 12, wherein thereinforcement assembly includes a plate.
 14. The trailer frame of claim12, wherein the axle section includes the sidewall and a top wallextending laterally outward from the sidewall, wherein the top wallterminates at a joint portion of the axle section; and wherein therearward section includes the sidewall and a top wall extendinglaterally outward from the sidewall, wherein upon attachment of the axlesection to the rearward section, the top wall of the rearward sectionextends over the sidewall of the axle section and lies adjacent to thetop wall of the axle section at an edge of the joint; and wherein thereinforcement assembly includes a reinforcing member attached to the topwall of each of the axle section and the rearward section at the joint.15. The trailer frame of claim 14, wherein the reinforcing member istack welded to the top wall of the axle section.
 16. The trailer frameof claim 14, wherein the reinforcing member includes a first portion anda second portion, where the first portion lies adjacent to the top wallof the axle section and is fastened to the axle section by a firstfastener, and wherein the second portion lies adjacent to the top wallof the rearward portion, wherein the second portion is attached to thetop wall of the rearward portion by a second fastener.
 17. The trailerframe of claim 16, wherein the first fastener is a tack weld and thesecond fastener is a Huck® bolt.